Guidelines for a Material Verification Program for New and ...

1 API RP 578 3rd edition, re written in new format. Clean copy no changes shown on this version 1st 2nd version, proposed for ballot 2/2017; revised from 1st ballot 1 15 16 .. JLYoakam Editor Page 1 of 26 Formatted: SuperscriptFormatted: Superscript Guidelines for a Material Verification Program for New and Existing Assets 1. SCOPE Purpose The purpose of this recommended practice (RP) is to provide the Guidelines for the owner /user to develop and implement a Material Verification Program (MVP) as part of an asset integrity quality assurance Program . The MVP uses PMI positive Material identification and other methods to verify that the nominal composition of an asset, an asset component, or weldment within the pressure envelope is consistent with the selected or specified construction materials.

2 A well designed and implemented MVP is an important tool one of the most important tools used to minimize the potential for catastrophic release of toxic or hazardous materials due to nonconforming materials of construction. liquids or vapors, and other general products contained. About this Document This RP provides the Guidelines for Material Verification programs involving ferrous and non ferrous alloys during the construction, installation, maintenance, and inspection of new and existing process equipment. This RP applies to metallic materials purchased for use either directly by the owner/user or indirectly through vendors, fabricators, or contractors and includes the supply, fabrication, and installation of these materials.

3 This Recommended Practice is applicable to all oil and petrochemical processing systems, and may be applied elsewhere at the discretion of the owner/user. It is intended to be applied by any owner/user wishing to verify and/or validate that the materials of construction received, fabricated, and/or installed are in accordance with Material specification(s). Material Verification Programs in General Methods for managing materials are part of an overall Quality Assurance Program or Quality Management system. Purchasing agreements should include clearly stated requirements related to chemical composition (including allowed trace or tramp elements), mechanical properties, critical dimensions, and other acceptance criteria.

4 The personnel involved in Material manufacturing and related quality assurance process must be suitably trained and qualified. Personnel must also have clear requirements related to their duties and up to date acceptance thresholds. Comment [JLY1]: Added this paragraph from item 51 resolved 5/2016 mtg; relocated from section Formatted: HighlightComment [JLY2]: This paragraph highlighted to indicate it is to be re written, items 12 29 from ballot 1, and as agreed 5/2016. Removed in 2nd ballot version, see email Ray Konet et al. Formatted: HighlightAPI RP 578 3rd edition, re written in new format. Clean copy no changes shown on this version 1st 2nd version, proposed for ballot 2/2017; revised from 1st ballot 1 15 16.

5 JLYoakam Editor Page 2 of 26 Formatted: SuperscriptFormatted: SuperscriptA clearly defined and documented process needs to be in place and understood by all personnel involved in the production, testing, and acceptance of Material . Periodic audits should be conducted at all stages to ensure that processes are being followed: that the techniques used to validate the materials meet requirements, and that processes are delivering consistent results. When MVP techniques identify materials that do not meet requirements, it is imperative to follow existing quality processes, and correct root causes identified processes that led to the nonconforming product.

6 Using the above with a well thought out and documented MVP process, PMI is invaluable in the overall achievement of 100% Material assurance. 2. REFERENCES Normative The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. API 510, Pressure Vessel Inspection Code: In service Inspection, Rating, Repair, and Alteration API 570, Piping Inspection Code: Inspection, Repair, and Rerating of In service Piping Systems API Recommended Practice 572, Inspection Practices for Pressure Vessels API Recommended Practice 574, Inspection Practices for Piping System Components API Recommended Practice 575, Guidelines and Methods for Inspection of Existing Atmospheric and Low pressure Storage Tanks API Recommended Practice 576, Inspection of Pressure Relieving Devices API Recommended Practice 577, Welding Inspection and Metallurgy API Recommended Practice 751, Safe Operation of Hydrofluoric Acid Alkylation Units API RP 939 C.

7 Guidelines for Avoiding Sulfidation Corrosion Failures in Oil Refineries Informative The following referenced documents are informative in the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. API RP 571, Damage Mechanisms Affecting Fixed Equipment In the Refining Industry API Recommended Practice 580, Risk Based Inspection API 579 1/ASME FFS 1 Fitness For Service ASME1 Boiler and Pressure Vessel Code: Section II Materials Formatted: HighlightAPI RP 578 3rd edition, re written in new format.

8 Clean copy no changes shown on this version 1st 2nd version, proposed for ballot 2/2017; revised from 1st ballot 1 15 16 .. JLYoakam Editor Page 3 of 26 Formatted: SuperscriptFormatted: SuperscriptPart A: Ferrous Material Specifications Part B: Ferrous Nonferrous Material Specificationss Part C: Nonferrous MaterialsSpecifications for Welding Rods, Electrodes, and Filler Metals Part D: Welding Rods, Electrodes, and Filler MetalsProperties ASME PCC 2, Repair of Pressure Equipment and Piping ASME , Process Piping CSB2 Chemical Safety Board Bulletin 2005 04 B, Positive Material Verification : Prevent Errors During Alloy Steel Systems Maintenance NACE3 Paper No 03651, Specification for Carbon Steel Materials for Hydrofluoric Acid Alkylation Units PFI4 ES22, Recommended Practice for Color Coding of Piping Materials Footnotes 1 ASME International, 3 Park Avenue, New York, New York 10016 5990, Chemical Safety and Hazard Investigation Board, Office of Prevention, Outreach, and Policy, 2175 K Street NW, Suite 400, Washington, 20037 1848, 202 261 7600, Most CSB publications are posted on, and can be downloaded from the CSB web site.

9 Nitrogen 6 11 3 NACE International , 1440 South Creek Drive, Houston, Texas 77218 8340, 4 Pipe Fabrication Institute, 511 Avenue of the Americas, #601, New York, New York 10011. DEFINITIONS AND ACRONYMS Definitions Alloy Material Any metallic Material (including welding filler materials) that contains alloying elements, such as chromium, nickel, or molybdenum, which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance. Alloys may be ferrous or non ferrous. based. Distributor A warehousing supplier for manufacturers or suppliers of materials or components.

10 Fabricator One An organization who which builds the assets affected by this recommended practice fabricates piping systems, or portions of a piping system, as defined by ASME Heat A batch of metal made at the same time, able to be traced from its original constituents and manufacturing process. API RP 578 3rd edition, re written in new format. Clean copy no changes shown on this version 1st 2nd version, proposed for ballot 2/2017; revised from 1st ballot 1 15 16 .. JLYoakam Editor Page 4 of 26 Formatted: SuperscriptFormatted: Inspection Lot A group of items or materials of the same type from a common source from which a sample is to be drawn for examination.